Intership At HARSHA ENGINEERS INTERNATIONAL.

LTD

A INTERSHIP REPORT

Submitted by

PATEL DEV JITENDRA

200320119016

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
in
Mechanical Engineering

[L J Institute of Engineering and Technology-Ahmedabad]

Gujarat Technological University, Ahmedabad

[AUGUST, 2023]
 L J Institute of Engineering and Technology
L J Campus, Near Sarkhej-Sanand Circle,
Makarba, Ahmedabad, Gujarat 382210

CERTIFICATE
This is to certify that the intership report submitted entitled intership at HARSHA

ENGINEERS INTERNATIONAL.LTD has been carried out by Patel Dev Jitendra under

my guidance in partial fulfillment for the degree of Bachelor of Engineering in Mechanical

Engineering, 7th Semester of Gujarat Technological University, Ahmadabad during the

academic year 2023-24.

Faculty Name Mr. Tushar Thakar

Internal Guide Head of the Department

 [Industry Letter Head]
Date: DD/MM/YYYY

TO WHOM IT MAY CONCERN

This is to certify that Patel Dev Jitendra, a student of L.J.INSTITUTE OF ENGINEERING

AND TECHNOLOGY has successfullycompleted his internship in the field of Maintenance

Department from 27/07/2023 to 10/08/2023 under the guidance of Mr.Mithun Chauhan.

His internship activities include <Internship Activities>.

During the period of his internship program with us, he had been exposed to different

processes and was found diligent, hardworking and inquisitive.

We wish him every success in his life and career.

For HARSHA ENGINEERS PVT.LTD

Authorized Signature with Industry Stamp

 L J Institute of Engineering and Technology
LJ Campus, Near Sarkhej-Sanand Circle,
Makarba, Ahmedabad, Gujarat 382210

DECLARATION
I hereby declare that the Internship report submitted along with the Internship entitled at

HARSHA ENGINEERS INTERNATIONAL.LTD submitted in partial fulfillment for the

degree of Bachelor of Engineering in Mechanical Engineering to Gujarat Technological

University, Ahmedabad, is a bonafide record of original intership work carried out by me at

HARSHA ENGINEERS INTERNATIONAL.LTD under the supervision of Mr.

MITHUN CAUHAN and that no part of this report has been directly copied from any

student’s reports or taken from any other source, without providing due reference.

Name of the Student Sign of Student

Patel Dev Jitendra

 ACKNOWLEDGEMENT

 I would like to express my sincere thanks to all those who helped me during my training.

 I’m very thankful to Mr. MITHUN CHAUHAN, who guided me during my whole
internship period and introduced me to other employees at HARSHA ENGINEERS
INTERNATIONAL. LTD, so that would help me with doubts in any point.

 I sincerely thanks to entire staff of HARSHA ENGINEERS INTERNATIONAL. LTD,

who gave their precious time to explain me the working of all machine at the place and
make me aware about the difference between theories and practical.

 I express my deepest sense of gratitude, profound respect & sincere thanks to all the
respondents who have helped me by providing necessary information.

i
 ABSTRACT

 Industrial training is an important phase of student’s life. A well-planned properly

executed and evaluated industrial training helps a lot in developing a professional attitude.
It develops an awareness of the industrial approach to problem-solving, based on a broad
understanding of the process and mode of operation of the organization.

 During two week of training at HARSHA ENGINEERS INTERNATIONL . LTD, at

MORAIYA. I learned about how to work on different types of well presses using
different types of machines.

 I learned about different types of processes which are applied on metal sheets. I also
learned about different types of self and manual operated press as well as wire cut EDM
machine and CNC & VMC machine .

ii
 List of Figures
Fig 1 Brass cage..............................................................................................................1
Fig 2 Steel cage...............................................................................................................2
Fig 3 Plyamide cage.......................................................................................................2
Fig 4 Stamed component................................................................................................3
Fig 5 Name of HARSHA ENGINEERS........................................................................3
Fig 6 MHS 1,2,3.............................................................................................................7
Fig 7 MPM 1,2,3,4.........................................................................................................8
Fig 8 Komatsu press m/c................................................................................................9
Fig 9 Vibrator...............................................................................................................10
Fig 10 Dryer..................................................................................................................10
Fig 11 Camera vision....................................................................................................11
Fig 12 Fogging..............................................................................................................11
Fig 13 ISGEC 500 T.....................................................................................................12
Fig 14 Degreasing m/c..................................................................................................13
Fig 15 Shot Blasting......................................................................................................13
Fig 16 Washing M/C.....................................................................................................14
Fig 17 Compressor........................................................................................................19
Fig 18 Air receiver tank................................................................................................19
Fig 19 Dryer..................................................................................................................20
Fig 20 Generator...........................................................................................................20
Fig 21 SMPS.................................................................................................................21
Fig 22 Lathe m/c..........................................................................................................25
Fig 23 RTSG.................................................................................................................25
Fig 24 Cylindrical Grinding m/c...................................................................................25
Fig 25 CNC....................................................................................................................26
Fig 26 Manual milling m/c.............................................................................................26
Fig 27 Wire cut EDM.....................................................................................................27
Fig 28 DMC 63V (VMC m/c)........................................................................................27

(iii)
Fig 29 Schuler 200 t..................................................................................................28
Fig 30 Camera vision system.....................................................................................30
Fig 31 CMM...............................................................................................................32
Fig 32 Induction motor............................................................................................36
Fig 33 Servo motor.....................................................................................................36
(iv)
 List of Tables
Table 1 Check list (VIBRATOR).................................................................................22
Table 2 Schuler Machine..............................................................................................28
Table 3 Induction motor & Servo motor......................................................................36
(v)
 Table of Contents
Acknowledgement...........................................................................................................i
Abstract..........................................................................................................................ii
List of Figures...............................................................................................................iii
List of Tables..................................................................................................................v
Table of Contents..........................................................................................................vi
Chapter 1 OVERVIEW OF THE COMPANY.........................................................1
1.1 Company overview...............................................................................................2
1.2 HARSHA ENGINEERS INTERNATIONAL.LTD.............................................4
( MORAIYA FIELD )
Chapter 2 INTODUCTION TO INTERSHIP...........................................................8
2.1 PURPOSE.............................................................................................................9
2.2 OBJECTIVE.......................................................................................................10
2.3 SCOPE................................................................................................................11
2.4 TECHNOLOGY.................................................................................................12
2.5 ROLES AND RESPONSIBILITY.....................................................................13
Chapter 3 TWO WEEK INTERNSHIP LEARNING............................................11
DAY 1 CUT & CARRY.........................................................................................14
DAY 2 SLA.............................................................................................................15
DAY 3 QUALITY PROCEDURE..........................................................................16
DAY 4 SUNADAY WEEK OFF............................................................................17
DAY 5 COMPRESSOR , GENERATOR & ELECTRICITY SYSTEM...............18
DAY 6 IR OF VIBRATOR.....................................................................................19
DAY 7 LOSSES OF ALL PRESS MACHINE.......................................................20
DAY 8 TOOL ROOM.............................................................................................21
DAY 9 SCHULER MACHINE & ASSEMBLY DEPARTMENT.........................22
DAY 10 CAMERA VISION SYSTEM...................................................................23
DAY 11 SUNDAY WEEK OFF..............................................................................24
DAY 12 CMM..........................................................................................................25
DAY 13 TYPES OF PRESS & TYPES OF CLUTCHES.......................................26
DAY 14 INFORMATION ABOUT PILLARS CONSIST BY TPM......................27
DAY 15 INDUCTION MOTOR & SERVO MOTOR............................................28
(vi)
References....................................................................................................................40
Appendix........................................................................................................................4
 CHAPTER 1
OVERVIEW OF THE COMPANY

1.1 COMPANY OVERVIEW

HARSHA ENGINEERS INTERNATIONAL LIMITED is a TPM certified precision Engineering
Company manufacturing Bearing cages and Stamped components which complies with good
manufacturing practices and adheres to the standards accepted by the industry.

Since its inception in 1986, Harsha Engineers International Limited* (Harsha) is the largest
manufacturer of precision bearing cages in organized sector in India in terms of capacity and
operations and amongst the leading manufacturers of precision bearing cages in the world with a
market share of approximately 5% to 6% in the organized segment of the global brass, steel,
polyamide bearing cages in terms of revenue.

Our principal production facilities are at Changodar and Moraiya, near Ahmedabad in Gujarat in
India. We also have production facility through subsidiary in Changshu, China and step down
subsidiary in Ghimbav Brasov in Romania.
PRODUCT:-
 BRASS CAGES :- BRASS CAGES HAVE SALIENT CHARACTERISTICS OF HIGH
RIGIDITY, HIGH STRENGTH AND IS SUITABLE FOR HIGH TEMPERATURE
OPERATING CONDITIONS.
They are classified in two types

Roller Cages
Ball Bearing Cages
 STEEL CAGES:- THESE ARE LIGHT IN WEIGHT, RELATIVELY HIGH IN
STRENGTH AND ABLE TO REDUCE FRICTION & WEAR.
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 They are classified in two types

Roller Cages
Ball Bearing Cages
 POLYAMIDE CAGES:- CAGES MADE OF HIGH-POLYMER MATERIALS ARE
LIGHTWEIGHT AND CORROSION RESISTANT.

Categories we offer:
Deep Groove Ball Bearings
Self-Aligning Ball Bearings
Cylindrical Roller Bearings
Angular Contact Ball Bearings
Taper Roller Bearings
Thrust Ball Bearings
Cylindrical Roller Thrust Bearings
Linear Ball Bearings
Water Pump Bearings
Other Special Types of Bearings
 STAMPED COMPONENTS:- IN RECENT YEARS, AUTOMOTIVE & INDUSTRIAL
STAMPING HAS EMERGED AS A KEY MARKET SEGMENT, WHEREIN WE
PROVIDE COMPREHENSIVE METAL STAMPING SOLUTIONS RANGING FROM
SIMPLE TO COMPLEX DESIGNS AND GEOMETRIES.
(2)
 APPLICATIONS-
Automotive Industry
Bearing and Sealing
Electrical & Appliance Industry

1.2 HARSHA ENGINEERS INTERNATIONAL.LTD

(MORAIYA FIELD)

Harsha Engineers International.Ltd at Moraiya field they have three manufacturing plants Steel
cages , Brass cages & Stamped components.

There are multiple department present in Moraiya field , I worked in maintenance department.

There are several machines which is use for produce the different products like: different
varieties steel cages & brass cages , different types of stamped components, Here also available
the camera vision system for measuring the component is ok or not.

Here safety is paramount importance in the industrial sector for various reasons:-
Protecting workers
Reputation
Avoiding Accidents , etc.

(3)
 CHAPTER 2
INTRODUCTION TO INTERNSHIP

2.1 PURPOSE
 Provides consultation , development and instruction seminars related to press machines
and how we upgrade it.
 Providing world class engineering services for all types of exploration and production
projects.
 At Harsha, manufacturing excellence is driven on a philosophy of using new age
technology to design and produce bearing cages and Stamped components with a focus on
cost, quality and manufacturing flexibility.
 We use tool design software like Pro Engineer for 3D modelling and detailing,
Numerically Controlled Tool Path, Auto Cad Stations, Sheet Metal Formability
Simulation , Hyperworks which allows us to eliminate any deviation in the design
process.

2.2 OBJECTIVE
 Objective is to learn how the learned concepts are applied in the real world and to get
familiar with the working of industry.
 Safety has the foremost priority in our high risk and disaster prone industry. We are now
more aware of the importance of industrial safety standards.
 To understand the "real" view of how operations are carried out in the Manufacturing
Industry.
 Our Research & Development initiatives have led through to innovations which have
been instrumental in improving manufacturing processes, reduced human error, enhanced
precision and saved energy across product verticals.
 Understand the technologies and tools used to solve the problem and learn the how to
solve technical problem and provide excellent user experience.

2.3 SCOPE
Harsha Engineers International.Ltd , refers to production of bearing cages and stamped
components that take place at India , China & Romaniya.

The scope of Harsha engineers International .Ltd includes:

o Manufacturing excellence is driven on a philosophy of using new age technology to
design and produce bearing cages and Stamped components with a focus on cost, quality
and manufacturing flexibility.
o Our tool room is equipped with machines like Hard Milling and Turning Machines, CNC
Wire-cut and EDM Machines with rotary electrodes, Axis Machining centre and various
high accuracy measuring instruments including CMMs to deliver precision quality
products.

2.4 TECHNOLOGY
Here are some technologies commonly used in bearing cage manufacturing company:
1. Injection Molding
2. Welding
3. Powder Metallurgy
4. Automation and Robotics
5. CAD/CAM Software
6. Material Science
7. Quality Control Technology
8. Lubrication and Coating
9. Documentation and Reporting
10. Regulatory Compliance

2.5ROLES AND RESPONSIBILITY

 ROLES :
- Designing
- Maintenance
- Testing
- Production
- Inspection
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(4)
 RESPONSIBILITES :

- Cost Management : Monitoring and controlling production costs to ensure

profitability while maintaining product quality
- Sales and Marketing Support : Collaborating with sales and marketing teams to
provide product information , samples and technical support.
- Maintenance : Regularly maintaining and repairing machinery and equipment to
prevent downtime and production disruptions.
- Health and Safety : Providing a safe working environment for employees, adhering
to safety regulations, and implementing protocols to prevent accidents.

(7)
 CHAPTER 3
TWO WEEK INTERNSHIP LEARNING

DAY 1 :- CUT & CARRY

TYPES OF PRESSES
For making the STEEL cages

A.) Minster Make Press

MHS- I machine ( 500 TONE )

STRAIGHTNER  which is use for uncoil the metal sheet.

FEEDER  Operate through servo motor and give the feed of sheet to the machining
operation.


This machine is works on the 6 main operations , which is given below.
1.) BLANKER  create a shape like a cup.
2.) PUNCH BOTTOM  cut the bottom part of cup.
3.) SIZER  finishing the upper layer of the cup.
4.) PERFORATOR  create a cage shape on the cup with the help of cutting slot tool.
5.) WINGER  remove the sharp edges from gernerate by the perforator operation.
6.) SPREADER  providing the little force at the bottom of the cage for the fitting
purpose.

 MHS – II ( 500 T )
 MHS –III ( 300 T )

(6)
B.) MPM Press Machine
There is the 4 types of MPM machine.which is describe below.
i. MPM-1 (150 T)
ii. MPM-2 (150 T)
iii. MPM-3 (150 T)
iv. MPM-4 (150 T)

7 operations carry out by MPM machine.

1.) BLANKER  create a shape like a cup.
2.) TRIMMING  in this step remove the some burr from the surface of cup or
also create a some slots on the periphery of the surface of cup.
3.) PUNCH BOTTOM  cut the bottom part of cup.
4.) SIZER  finishing the upper layer of the cup.
5.) PERFORATOR  create a cage shape on the cup with the help of cutting slot
tool.
6.) WINGER  remove the sharp edges from gernerate by the perforator
operation.
7.) SPREADER  providing the little force at the bottom of the cage for the
fitting purpose.

 Transfer Bar  which is use for the movement of part from one machining operation to
the next operation.

Here shafting mechanism is use for operate the transfer bar.

 Lubrication oil is provide to the tool at every interval of time with the help of induction
motor , which use for the machining operation.
 This is the pneumatic type press machine because the presser is generate by the help of
compressed air.
 60 HP motor is used for carry out the pressing operstion.

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C. ) KOMATSU Press Machine (200 T)

STRAIGHTNER  Hydraulically uncoil the sheet.

FEEDER  Operate through servo motor and give the feed of sheet to the machining
operation.

This machine is works on the 6 main operations , which is given below.

1.) BLANKER  create a shape like a cup.

2.) PUNCH BOTTOM  cut the bottom part of cup.
3.) SIZER  finishing the upper layer of the cup.
4.) PERFORATOR  create a cage shape on the cup with the help of cutting slot tool.
5.) WINGER  remove the sharp edges from gernerate by the perforator operation.
6.) SPREADER  providing the little force at the bottom of the cage for the fitting
purpose.
 Knogh out operation for the component is done by Servo motor & Hydraulic motor.
 Transfer bar is operate with the help of the servo motor mechanism.
 In transfer bar 3 motors are used .
One motor for forward & reverse direction motion.
Two motors are used for open and close transfer bar.

(8)
C.) VIBRATOR
 After receiving the component from the press machine , some number of components are
going to the vibrator by counting with the help of sensors.
 In the vibrator , clean the component & remove the excessive lubrication oil from the
surface of the component.
 Here in the large quantitive of small rock elements are use for remove the excessive oil
from the component.
 Washing the component by using the mixture of water and chemical.
 Glydol checical is use about 25% & water is use about 75%.

D.) DRYER
 In this system the heater element is use for dry the parts which is coming from vibrator.

E.) CAMERA VISION SYSTEM

 These system is use for detect the defect in the workpiece and use for reject the damage
part which is collected by drop box.
 Generally here 5 cameras are use for detect the defects and improving the accuracy for the
production.

(10)
F.) FOGGING
 This is the final step of the produce the bearing cage.
 In this method some number of components are going into the fogging chamber and
supplying the mixture of Oil and Air.
 This system is required when the components are store for the long time.
 By using this system component is protect from the envirormental condition.

(11)
DAY :-2 SLA (SINGLE LINE AUTOMATION)

OPERATIONS :-
STRAIGHTNER  which is use for uncoil the metal sheet.

FEEDER  Operate through servo motor and give the feed of sheet to the machining
operation.


1.) ISGEC PRESS MACHINE(500 TONE)  which is making cups directly from the steel sheet.
 cluth is hydraulically operated.


2.) FACING  For making the finish cup from the upper layer.

3.) Notching  Create a slots on the side wall of cup for making the bearing cage.
 This is 40 tone notching machine.

4.) Coining  This machine is use for removing the sharp edges which is generated during the
Notching operation and its also 40 tone machine.

(12)
5.) Spreader  It’s a hydraulic press which is provide the little force at the bottom for better
fitting.

6.) Degreasing machine  Degreasing machine is use for clean the bearing guage and remove
the dust particles.
TRICHLOROETHYLENE TYPE 1 chemical is use for cleaning.
Its consist the 3 tanks at the different temperature.
Tank 1 - Using the heater and maintain temperature at 60 to 70 degree.
Tank 2 - Temperature at 50 to 60 degree.
Tank 3 - Use of heater the temperature is maintain at 85 to 90 degree
and also use the cooling system for preventing the lose of
chemical.

7.) SHOT BLASTING  This system is use for the apply the other layer on the bearing cage
according to the customer requirement.
Commonly use for the surface treatement.
Ex.S170,S110,Steel cut wire shots are generally use for these treatement.

(13)
 
8.) WASHING MACHINE  Ferrocote 5856 BFNM chemical is use.
 Supplying the oil for the better protection of bearing cages from
the environmental condition.

9.) VISUAL INSPECTION  Visual inspection is a technique for detecting defects using the
naked eye to ensure equipment is working properly or that
manufactured products are being made to specification.

10.) PACKAGING  This is the final step of the production. Here all the product are pack in plastic
bags and then after it put inside the wooden box.

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DAY 3 :- QUALITY PROCEDURE

Equipement / Maintenance TBM (Time Base Maintenance) / IR (Inspection and Repair)

1.) PURPOSE :- It is use for prepare the guidelines for carring out machine equipement time
bas maintenance to improve reliability & maintainability of machine.

2.) SCOPE :- Is applicable to all S,A and B class machine of manufacturing in Changodar
and Moraiya plant.

3.) RESPONSIBILITY AND AUTHORITY :-

Established By – HOD maintenance

Reviewed, Approved & Issued By – HOD Quality Management System
Implemented By – HOD maintenance , HOD manufacturing

4.) DEFINITIONS :-

TBM/IR :- It’s the treatement given to the equipement to eliminate the unwanted failure
of equipements. It requires the equipement at stop condition.

S-CLASS MACHINE :- Most critical machine in items of achieving production targets,if

Failure occurred.

A-CLASS MACHINE :- Critical equipement in terms of achieving production targets.

B-CLASS MACHINE :- Less critical than A class.

USER DEPARTMENT :- Maintenance department is a user department.

5.) ACTIVITIES :-

 User Department
 Production Department
 Responsibility
 Control Point
 Reference / Records Documents

Flow Chart Of User Department (Maintenance)

START

PREPARE THE MASTER LIST OF

EQUIPEMENT / MACHINE LIST

(15)
IDENTIFY THE CHECK POINTS &
FREQUENCY AS PER MANUAL

DEVELOP TBM / IR
CHECK SHEET

DEVELOP TBM / IR
SCHEDULE

CONSENSUS OF TBM/IR SCHEDULE

WITH PRODUCTION DEPARTMENT

APPROVAL OF
TBM/IR SCHEDULE

CHECK THE NO
AVAILABILITY OF
THE EQUIPEMENT

RE-ADJUST TBM/IR
SCHEDULE
YES

EXECUTE TBM/IR AS PER

CHECK LIST
 HAND OVER EQUIPEMENT / MACHINE TO
PRODUCTION

C B

CHECK PART
QUALITY &
EQUIPEMENT
PERFORMANCE

NOT OK

TAKE COUNTERMEASURE
OK

UPDATE THE RECORDS.

REVISION OF IR CHECK POINS BASED ON

ANY IMPROVEMENT POINT OBSERVED
DURING TBM/IR.
(IF REQUIRED)

END

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 6.) OUTPUT :-

 TBM/IR executed check sheet / list.

 Machine history sheet.

7.) MESUREMENT & MONITORING :-

8.) SUPPORTING DOCUMENT :-

 Procedure
 Work Instruction
 Reference Documents

9.) RECORDS :- A record is any document – in any format (paper or electronic , and yes
even video) – created or received by you or your department – that allows you to conduct
business.

DAY 4 :- SUNDAY WEEK OFF ( HOLIDAY )

DAY 5 :- COMPRESSOR , GENERATOR AND ELECTRICITY SUPPLY SYSTEM

COMPRESSOR :-

An air compressor works by drawing in air from the surrounding environment and then
compressing it to increase its pressure. This is typically achieved using a piston, rotary screw, or
centrifugal mechanism. The compressed air is then stored in a tank or reservoir at a higher
pressure. This stored air can be used for various applications such as powering pneumatic tools,
inflating tires, or operating machinery. The compressor's motor provides the energy needed to
drive the compression process. The size and type of compressor can vary depending on the
intended use and the amount of air pressure required.

HARSHA ENGINEERS has 4 type air compressor all are describe below:

I. KAESER  Machine class = A

Max Capacity = 745 CFM (Cubic Foot Per Minute)
6.5 bar pressure is generally use

II. ATLAS COPCO  Machine Class = A

Max Capacity = 521 CFM

III. ATLAS CPCO  Machine Class = A

Max Capacity = 148 CFM
(18)
IV. ATLAS COPCO  Machine Class = A
Max Capacity = 284 CFM

AIR RECEIVER TANK  An air receiver tank stores compressed air from a compressor,
reducing moisture and fluctuations in pressure. It allows for stable air
supply during peak demands, acting as a buffer. Compressed air
cools and condenses, aiding moisture removal. This enhances
efficiency and prolongs equipment life in various industrial
applications.

(19)
 

KAESER DRYER  An air dryer removes moisture from compressed air to prevent corrosion
and equipment damage. It cools the air, causing water vapor to condense.
and be removed. Then, the dry air is reheated before entering the system.
This ensures clean, dry air for efficient and reliable operation in various
industrial processes.

 Max Capacity = 550 CFM

In last step the dry air is supply to the machine according to the requirement of machines.

GENERATOR :- Super nova generator  700 litre storage tank of Diesel


650 KVA power produce

WORKING - A generator converts mechanical energy into electrical energy through

electromagnetic induction. When the generator's rotor spins within a magnetic
field, it produces an alternating current (AC). This AC is then converted into a
stable voltage using components like diodes and an AVR (Automatic Voltage
Regulator). The resulting electrical output can power various devices and system.

(20)
ELECTRICITY SUPPLY SYSTEM :-

11 KVA supply through the electrical pillar from GEB


High Tension Breaker

Down Grade Transformer (convert from 11 KV to 415 V )

Stabilizer
( Maintain the voltage )

Main GEB power breaker

RTCC Panel :- Rtcc Is “remote Tap Changer Control “which Is a Programmable Device to
control the output of the transformer through OLTC unit fitted in the transformer
trough control cables.

APFC Panel :- (AUTOMATIC POWER FACTOR CONTROLLER)

APFC Panel has microcontroller based programmable controller which switches
the capacitor banks of suitable capacity automatically in multiple stages by
directly reading the reactive load (RKVA) which works in the principle of VAR
sensing tends to maintain the PF to 0.99 Lag.

SMPS :- The full form of SMPS is Switched Mode Power Supply.

SMPS is an electronic power supply system that makes use of a switching
regulator to transfer electrical power effectively.

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DAY 6 :- IR (INSPECTION AND REPAIR) OF VIBRATOR

MACHINE STEP STATUS :-

1. Initial Cleaning
2. Counter Measure Against SOC ( source of contamination)
3. Tentative Standard
4. General Inspection  Six sub system
i.) Nut & Bolt
ii.) Lubricating
iii.) Electrical
iv.) Pneumatic
v.) Hydraulic
vi.) Transmition
5. Autonomous Maintenance
6. Standardization
7. All Out Autonomous Maintenance
 CHECKLIST : VIBRATOR (QUATERLY IR CHECK)

Sr Division M/c Name M/c No Method of Tools

No. C & C Vibrator Vibro - 5 checking
Sub Assembly Checked-Item

1. Main Motor Clamping bolt No loose,thread damage Tightening Spanner

Bracket No wear Inspection Hand
Bearing No dirt,damage,dry Inspection Hand
Weight block No loose, damage Inspection Hand
Motor Mounting No loose mounting Tightening Spanner

2. Bowl-Vibrator Looking bolt No loose, threading Tightening Spanner

Tapper washer No damage Inspection Hand
Lining No crack, no damage Visual ins. Eye
Flapper No loose , no damage Inspection Hand
3. Base-Vibrator Compression No loose , crack, no Inspection Eye , Hand
spring damage
Mounting pad No thread damage,no Tightening, Eye ,
bolt loose inspection spanner
4. Pneumatic FRL unit No leakage, damage Inspection Eye , Hand
system Pipe&connection No leakage, damage Inspection Eye , Hand

Etc. there are many things to be consider for inspection and repair of machine.
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DAY 7 :- LOSSES OF ALL PRESS MACHINE

1) Failure Loss :- The time taken for repair or replacement of decoiler , feeder , transfer bar
and any other part of the machine shall be included in loss no.1.

- Feeder variation
- CAM offset
- Transfer bar bend
- Fault in FRL unit
- Break the timing belt

2) Setup & Adjustment Loss :- Time measure from the last piece of continuous part to the
100 okay piece of new part.

- Remove the lifting pin

- Remove the set of last piece
- Add the new block
- Clamping the new block

3) Cutting Blade Loss :- All the time spent in polishing , grinding or changing of any tool
for more than ten minutes and after changing or setting the quality after polishing ,
grinding work till starting the machine should be booked in CBL Loss 3 no.

a) Blanker station
b) Punch bottom station
c) Trimming station
d) Sizer station
e) Perforator station
f) Winger station
g) Spreading station

4) Startup Loss :- Time taken to start up the running machine from the start of the shift to
the start up time called loss.
- No power
- No air
- Time to remove the scrap from the back of the machine.

5) Minor stoppage loss :- If the machine is stopped for less than 10 minute then it is
counted as minor stoppage from one to nine minutes.

6) Speed Loss :- When machine is runs at aspeed less thn its standard speed , it is called
speed loss.

7) Defect & Reward Loss :- The time of machine is used for reworking the NC material or
the time for machine has to be shut down is called rework loss.
- Coil bend issue
- Transfering setting for top damage
- Settings in the tool for any type of dent
- Setting in spreader & winger for stuck punch
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8) Shutdown Loss :- Any time a machine is shut down for planning or for any activity other
than production is considered as shut down loss.

- Out of order
- Week off
- Training
- PPAP/NPD sample

9) Management Loss :- The time spent in TPM activities , material , tool , power provided
by the management of the company or meeting organized by the company is called
management loss.

- Quiz time
- Meeting
- JH (JISHU HUZEN) time
- Lunch time

10) Motion Loss :- For any processs the time taken to bring or carry material / tools is called
motion loss.
- Time taken for transportation

11) Line Organization Loss :- If the machine has to be shut down due to WIP or Cup , then
the loss is called line organization loss.

- Absence of basket
- Absence of cup
- Excessive WIP (work in progress)

12) Failure To Automate Loss :- The time from when the machine stops due to loss of raw
material and restarts the machine after inserting new material is called failure to
automated loss.

13) Measurement & Adjustment Loss:- If the part running across your machine is as per
the drawing but any dimension of its running on the lower or higher side and set that
dimension in the center while the amchine is stopped during the setting or measurement ;
this type of time loss is called Measueent & Adjustment loss.

- Setting of closing
- Setting of Bottom G
- O.D setting
- Setting of assembly
- Setting of slug entry in perforator

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DAY 8 :- TOOL ROOM

1. Lathe Machine :- A lathe machine rotates a workpiece while a cutting tool shapes it,
creating various shapes like cylinders or cones. It's used for precision turning, threading,
and facing operations. The workpiece is secured on the spindle, and the tool moves along
its axis, cutting material to the desired dimensions and finish .

2. RTSG ( Rotary Surface Grinding Machine) :- A rotary grinding machine uses an

abrasive wheel to remove material from a workpiece's surface. The workpiece is held in
place while the grinding wheel spins, making contact and gradually wearing away the
material. This process is used for precision shaping, smoothing, and finishing of various
materials, such as metal or wood.

3. Cylindrical grinding machine :- A cylindrical grinding machine is used to shape the

exterior of a workpiece. The workpiece is mounted on a center or held in a chuck, and a
grinding wheel rotates against its surface. As the wheel moves, it removes material,
creating a cylindrical shape. This process is used for achieving high precision and
smoothness in cylindrical parts like shafts or rods.

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4. CNC Machine :- A CNC (Computer Numerical Control) machine is a manufacturing tool
that uses computerized instructions to control the movement of the machine's tools and
parts. It replaces manual control with automated processes, enabling high precision and
efficiency in tasks like cutting, milling, drilling, and more. CNC machines are widely
used in industries for producing complex and precise components.

5. Manual Milling Machine :- In a manual milling machine, a rotating cutter removes

material from a workpiece. The workpiece is secured on a table that can move in different
directions (X, Y, and Z axes). The operator adjusts the cutter's position and depth
manually, controlling the cutting process. It's a versatile tool for shaping and cutting
materials like metal or wood, but it requires manual skill and precision from the operator.

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6. Wire cut EDM (Electro Discharge Machining):- Wire Cut Electrical Discharge
Machining (EDM), often referred to as Wire EDM, is a manufacturing process used to cut
intricate shapes and profiles in conductive materials using a thin, electrically charged
wire. In this process, a rapidly moving, electrically charged wire is used to erode material
from the workpiece, creating precise and complex shapes. Wire EDM is commonly used
in industries like aerospace, automotive, and electronics manufacturing for applications
that require high precision and tight tolerances.

7. DMC 63V (VMC (vertical milling center) M/C) :- A vertical milling center (VMC) is
a machine used for precision machining of materials. It utilizes a vertically oriented
spindle to rotate cutting tools, allowing them to remove material from a workpiece held
on a table. VMCs are versatile and commonly used for producing complex components in
industries such as manufacturing and engineering.

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DAY 9 :- SCHULER MACHINE & ASSEMBLY DEPARTMENT

SCHULER M/C (200 tone):

Specifications of Machine :-
Year of construction 2005
Nominal force 2000 KN
Nominal power way 8 mm
Nominal stroke 160 rpm
Speed stroke 20-100 /min
Rotational speed of flywheel max 1015/min
Compressed air 6 bar
Tool dimension max 2000*1000*540 mm
Stop time 0.817 sec
Safety distance 380 mm
Tool weight w/o accessories 37 tone

This machine is generally use for produce the stamped component.

Machine Class - S
M/C cycle time - 60
Function - Cage making

Generally , This machine is works on the 6 main operations. which is given below :

1.) BLANKER  create a shape like a cup.

2.) PUNCH BOTTOM  cut the bottom part of cup.
3.) SIZER  finishing the upper layer of the cup.
4.) PERFORATOR  create a cage shape on the cup with the help of cutting slot tool.
5.) WINGER  remove the sharp edges from gernerate by the perforator operation.
6.) SPREADER  providing the little force at the bottom of the cage for the fitting
purpose .

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ASSEMBLY DEPARTMENT : -

The assembly department for making tools is a critical phase in tool manufacturing. Skilled
technicians gather individual components, such as handles, blades, and fasteners, and
meticulously assemble them into functional tools. This department ensures that each tool is
correctly aligned, calibrated, and tested to meet quality standards. It involves precision work,
attention to detail, and often utilizes specialized tools and techniques to ensure proper
functionality and safety. A well-organized assembly department plays a pivotal role in producing
reliable and efficient tools that cater to various industries, ranging from construction and
automotive to electronics and woodworking.

Every tool or tool blades which are use in the machining operation its first to be done coated with
the TIN.

After assemble the tool then its go for checking with manually and lastly its check on the trial
machine ( Minster press 175 tone or IXP-125).

ADVANTAGES Of TIN Coating :

- High hardness and adhesion

- Good ductility
- Excellent lubricity
- High chemical stability
- Tough resistance to wear , corrosion & temperature

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DAY 10 :- CAMERA VISION SYSTEM

A camera vision system is a technology used to inspect and verify materials in various industries,
such as manufacturing, quality control, and automation. It employs cameras, image processing
algorithms, and software to analyze visual data and make informed decisions.

The process begins with a camera capturing images or videos of the material under examination.
These images are then processed using sophisticated algorithms that detect and extract features,
patterns, or defects. These algorithms can identify variations in color, shape, size, texture, and
even minute defects that might be imperceptible to the human eye.

The extracted data is compared to predefined standards or specifications, allowing the system to
classify the material as acceptable or defective. This decision triggers appropriate actions, such as
sorting, rejection, or further analysis. The success of the camera vision system relies on the
accuracy of the algorithms, the quality of the camera, and proper lighting conditions.

Advanced systems may incorporate machine learning techniques, enabling them to adapt and
improve their performance over time by learning from a vast dataset of images. This helps in
handling variations in materials and detecting new types of defects.

In summary, a camera vision system employs cameras and intelligent algorithms to capture,
process, and analyze visual data, ensuring that materials meet specified quality standards by
detecting defects, variations, or irregularities in real-time.

DAY 11 :- SUNDAY WEEK OFF ( HOLIDAY )

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DAY 12 :- CMM (COORDINATE MEASURING MACHINE)

The Coordinate Measuring Machine is a flexible type measuring device capable of measuring
position of any location on the product / component along three mutual perpendicular axex.

Elements Of CMM

1 Machine Structure
2 Sensing Probe
3 Machine Control Unit (MCU)
4 CMM Software

(1) Machine Structure :- The rigid framework or structure of the CMM provides stability and
reference point for accurate measurements. The CMM's axes
(usually X, Y, and Z) allow controlled movement of the probe to
different positions on the object being measured.

(2) Sensing Probe :- A sensing probe in a Coordinate Measuring Machine (CMM) touches an
object's surface, triggering measurements. Touch-trigger probes record
data points upon contact, while continuous-contact scanning probes
capture data while moving along the surface. This data is used to create
precise 3D models and measurements for analysis.

(3) Machine Control Unit (MCU) :- The machine control unit in a Coordinate Measuring
Machine (CMM) manages the movement of the
machine's axes based on measurement instructions. It
interprets data from the probe, coordinates axis
movement, and ensures accurate positioning. This unit,
often driven by specialized software, translates
measurement programs into precise movements, allowing
the probe to gather data points and create detailed 3D
representations of objects for analysis and quality control.

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 (4) CMM Software :- CMM software plays a pivotal role in a Coordinate Measuring
Machine's (CMM) operation. It allows users to create measurement
programs, define measurement tasks, and analyze results. The
software interfaces with the machine control unit to guide the probe's.
movement, collect data points, and generate detailed 3D models. It
often incorporates CAD data for comparison, ensuring accurate
measurements and aiding quality control and inspection processes.

ADVANTAGES OF CMM :-

- High Accuracy - Quality Assurance

- Versatility - CAD Integration
- Efficiency - Complex Geometries
- Repeatability
- Data Visualization

LIMITATION :-
- Operator Skill
- Probe wear
- Environmental conditions
- Cost

APPLICATION :-
- Automotive
- Aerospace
- Medical
- Manufacturing
- Defense
- Heavy Machinery

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DAY 13 :- TYPES OF PRESS & TYPES OF CLUTCHES

TYPES OF PRESS :-

 HYDRAULIC PRESS : Utilizes hydraulic force to compress materials. It's commonly

used for metal forming, forging, and deep drawing.

 MECHANICAL PRESS : Relies on mechanical force to perform tasks like blanking,

piercing, and stamping.

 PNEUMATIC PRESS : Operates using compressed air or gas to exert force. It's often
used for light-duty tasks such as riveting and bending.

 SERVO PRESS : Uses a servo motor for precise control of force and speed. This type is
favored for tasks that require high accuracy.

 ROTARY PRESS : Features a rotating turret that allows for multiple operations to be
performed on a single workpiece.

 SCREW PRESS : Employs a screw mechanism to apply pressure, commonly used for
forging and extrusion.

 ARBOR PRESS : Hand-operated press with a lever mechanism, used for tasks like
assembly, riveting, and pressing.

 FLY PRESS : Operated manually or using a flywheel, it's suitable for small-scale
pressing tasks.

 H-FRAME PRESS : Has an "H" shaped frame and is often used for heavy-duty tasks like
bending, straightening, and pressing.

 C-FRAME PRESS : Resembles the letter "C" and is versatile for tasks like punching,
coining, and bending.

 COINING PRESS : Designed for precision and high-pressure applications like coin
minting or producing intricate details.

 FORGING PRESS : Specifically designed for forging processes, providing high force for
shaping metal.

These press machines serve diverse industrial needs and are used across manufacturing,
fabrication, and other sectors for shaping, forming, and processing materials.

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TYPES OF CLUTCHES :-

A clutch is a mechanical device used in machinery and vehicles to engage and disengage power
transmission between rotating parts, typically an engine and a gearbox or transmission. It allows
for smooth starts, stops, and shifts without damaging the components involved.

i. FRICTION CLUTCH : This is the most common type of clutch, found in vehicles with
manual transmissions. It uses friction between a clutch plate and flywheel to engage and
disengage the engine from the transmission.

ii. CENTRIFUGAL CLUTCH : Used in small engines like lawnmowers and mopeds, this
clutch engages based on the engine's rotational speed. As the engine speeds up,
centrifugal force causes the clutch shoes or weights to move outward, engaging the
clutch.

iii. HYDRAULIC CLUTCH : Employed in vehicles with manual transmissions, this clutch
uses hydraulic fluid to transmit the clutch pedal's force to the clutch mechanism, offering
smoother engagement and disengagement.

iv. ELECTROMAGNETIC CLUTCH : Utilized in applications where remote engagement is

needed, such as in some industrial machinery. An electromagnetic field is used to control
the clutch's engagement.

v. DOG CLUTCH : Often used in machinery, this type of clutch has teeth or "dogs" that
engage with mating teeth on another component, providing a quick and positive
connection.

vi. CONE CLUTCH : Employed in applications requiring high torque transmission, like
heavy machinery. It uses friction between conical surfaces to engage and disengage.

vii. MULTI-PLATE CLUTCH : Used in high-performance vehicles, it consists of multiple

interleaved clutch plates for increased torque capacity.

viii. WET CLUTCH : Often used in motorcycles and some automatic transmissions, this
clutch is immersed in an oil or fluid bath to dissipate heat and reduce wear.

ix. DRY CLUTCH : Found in some motorcycles and automotive applications, this clutch
operates without being immersed in a fluid, relying on friction materials to engage.

x. BELT-DRIVEN CLUTCH : Common in some industrial applications, this type of clutch

uses belts to transmit power between pulleys.

These are just a few examples of the many types of clutches, each designed to suit specific needs
and applications.
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DAY 14 :- INFORMATION ABOUT PILLAR’S WHICH IS CONSIST BY TPM

TPM (Total Productive Maintenance) consists of eight key pillars, each addressing different
aspects of improving equipment reliability, maintenance efficiency, and overall operational
effectiveness.

These pillars are:

1) Jishu Hozen (Autonomous Maintenance): As I mentioned earlier, this pillar focuses on

empowering operators to take care of routine maintenance tasks and inspections to
prevent breakdowns and keep equipment in good condition.

2) Kobetsu Kaizen (Focused Improvement): This pillar involves identifying and addressing
specific problems and inefficiencies in the production process to continuously improve
equipment performance and overall efficiency.

3) Planned Maintenance: This pillar emphasizes scheduled maintenance activities to

ensure that equipment remains in good working condition and to minimize unplanned
downtime.

4) Quality Maintenance: In this pillar, efforts are directed towards ensuring that the
equipment produces quality products consistently by preventing defects and issues.

5) Training and Education: TPM involves training and educating employees at all levels to
improve their skills and knowledge, contributing to better equipment operation and
maintenance practices.

6) Early Equipment Management (EEM): EEM focuses on incorporating maintenance

considerations during the design and installation of new equipment to enhance its long-
term reliability and ease of maintenance.

7) Office TPM: This pillar extends the TPM principles beyond the production floor to the
office and administrative areas, aiming to improve processes, reduce waste, and enhance
efficiency in non-production functions.

8) Safety, Health, and Environment (SHE): Ensuring a safe and healthy work
environment is crucial. This pillar integrates safety and environmental considerations into
TPM practices.

By implementing and nurturing these eight pillars, organizations can achieve a holistic approach
to maintenance, production, and overall operational excellence.

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DAY 15 :- INDUCTION MOTOR & SERVO MOTOR

Sr Particular Induction Motor Servo Motor

No.

1. Feedback Induction motor is an open loop Servo motor is closed loop system
mechanism system

2. Inertia An induction motor has high Servo motor has a very low inertia ,
inertia Hence servo motors are used in
applications where instant and
accurate positioning of load is required

3. Stator Induction motor stator is formed Servo motor stator is formed with
by coils permanent magnet

4. Application While in application where at Servo is very easy to stop at instant ,

instant position stop is not So it is used in position control
required induction motor is used. appication

5. Torque Induction motor delivers pure Servo motors deliver controlled torque
delivery uncontrolled torque

6. Speed In induction motors , only speed Servo motor speed and position can be
control can be adjusted adjusted and controlled with greater
precision

7. Cost Induction motor is cheaper Servo motor is twice compared to

compared to servo motor induction motor

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